Graco PRO AA4000 Instructions Manual
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Graco PRO AA4000 Instructions Manual

Air-assisted airless spray gun
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INSTRUCTIONS–PARTS LIST
307–706
Rev. R
Supersedes P
This manual contains IMPORTANT
WARNINGS AND INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
Model PRO AA4000
MANUAL MID-RANGE ELECTROSTATIC
AIR-ASSISTED AIRLESS SPRAY GUN
66 bar (950 psi) MAXIMUM WORKING FLUID PRESSURE
7 bar (100 psi) MAXIMUM WORKING AIR PRESSURE
Part Number 218–668, Series B
With 0.279 mm (0.011 in.) spray tip, part no. 219–411
U.S. Patent No. 4,290,091; 4,219,865;4,386,739; 3,843,052;
4,462,061; 4,497,447; 4,554,622
U.K. Patent No. 2,140,327B; 2,111,406B; 2,142,559B; 2,147,158
Patented 1986, 1987 Canada
Brevete 1986, 1987
French Patent No. 82 21202; 84 07942; 84 10234
Italian Patent No. 1,111,380
West German Patent No. DE 22 09 896
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1984, GRACO INC.

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  • Page 1 Patented 1986, 1987 Canada Brevete 1986, 1987 French Patent No. 82 21202; 84 07942; 84 10234 Italian Patent No. 1,111,380 West German Patent No. DE 22 09 896 GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 COPYRIGHT 1984, GRACO INC.

  • Page 3: Table Of Contents

    Gun Operation Troubleshooting Chart ..Graco Phone Numbers ..... . . Electrical Troubleshooting Chart .

  • Page 4: Safety Warnings

    SAFETY WARNINGS SERIOUS BODILY INJURY, EXPLOSION, FIRE, OR ELECTROSTATIC SHOCK CAN OCCUR IF THE PRECAUTIONS BELOW ARE NOT FOLLOWED. READ AND UNDERSTAND ALL INSTRUCTION MANUALS, TAGS, AND WARNING LABELS BEFORE OPERATING EQUIPMENT. ELECTROSTATIC EQUIPMENT SHALL ONLY BE INSTALLED AND USED BY TRAINED, QUALIFIED PERSONNEL WHO SHALL BE FULLY CONVERSANT WITH THE REQUIREMENTS STATED WITHIN THIS INSTRUCTION MANUAL.
  • Page 5 3. Electrostatic Spray Gun: obtain grounding through connection to a Use only non-sparking tools to clean residue from the booth and hangers. properly grounded air supply hose. Use only the Graco Electrically Conductive Air Supply Hose; see ACCESSORIES section to order.

  • Page 6: Typical Installation

    Air Supply to Gun MUST Be Interlocked purchased separately . See ACCESSORIES. NOTE: Solenoid With Spray Booth Exhaust Fan. V alve (B) is not offered as a Graco accessory ., Pump Ground Wire Air Hose Ground Wire Main Air Supply Line...

  • Page 7: Ventilate The Spray Booth

    (Y) and a true earth ground (Z). Use an applied electrically connected to a true earth ground. Use voltage of 500 volts minimum to 1000 volts maxi- only Graco Electrically Conductive Air Supply mum . See Fig 1. Hose. See ACCESSORIES.

  • Page 8: Connect The Fluid Line

    INSTALLATION Connect the Fluid Line WARNING (See Typical Installation) The fluid drain valve (V) is required in your system to Before connecting the fluid line (N), blow it out assist in relieving fluid pressure in the displacement with air and flush it with solvent. Use solvent which is pump, hose and gun;...

  • Page 9: Install The Spray Tip And Air Cap

    OPERATION Install the Spray Tip and Air Cap First, complete all the checks under the Operat- ing Checklist on page 9. Then turn the ES ON-OFF WARNING valve lever (T) to ON. See Fig 5. For your safety, always follow the Pressure Relief Procedure, on page 4, before installing, or remov- Provide a 3.1 bar (45 psi) clean, dry, regulated air ing the spray tip or air cap.

  • Page 10: Maintenance

    MAINTENANCE Daily Care and Cleaning c. Use a soft brush or other soft tool, with an air blow gun, to clean air cap passages. Take care CAUTION not to scratch any surfaces. If air cap holes are Clean all parts with a non–conductive solvent, plugged, use a round toothpick to unplug the compatible with the fluid being sprayed.

  • Page 11: Spray Pattern Troubleshooting Chart

    SPRAY PATTERN TROUBLESHOOTING CHART WARNING Installing and servicing this equipment requires access to parts which may cause electrostatic shock or other seri- ous bodily injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified.

  • Page 12: Gun Operation Troubleshooting Chart

    GUN OPERATION TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Air leakage from front of Air valve not seating properly. Clean, service. See page 21. gun. Air stem packing too tight. Loosen packing. See page 21. Fluid leakage from Loose or worn fluid seat. Tighten or replace fluid seat and/or electrode.

  • Page 13: Electrical Troubleshooting Chart

    8. Gun not properly grounded. See Check the Electrical Grounding, page 7. Be sure Graco air supply hose is being used and is properly grounded. Operator gets mild Work piece not properly Clean work piece hangers. Check grounded.

  • Page 14: Electrical Tests

    ELECTRICAL TESTS The performance of the spray gun is directly affected by the condition of the electrical components contained Gun Handle inside the gun. The electrical tests below can be used to 32a Air Inlet Fitting Megohmmeter determine the condition of the power supply (3) and the Electrode ball housing and resistor (14) as well as the continuity of the electrical path between components.

  • Page 15: Test Resistor Stud Resistance

    ELECTRICAL TESTS Test Resistor Stud Resistance Gun Barrel Insert a conductive rod (JJ) into the gun barrel (removed Megohmmeter for the power supply test) and against the metal contact Conductive Rod (KK) in the front of the barrel. See Fig 9. Metal Contact Electrode Measure the resistance between the conductive rod (JJ)

  • Page 16: Service

    SERVICE Gun Disassembly NOTE: A box of ten electrodes is included in the tool kit (63). WARNING Installing and servicing this equipment requires Ball Seat Housing & Resistor Replacement access to parts which may cause electrostatic shock or other serious bodily injury if the work is not Unscrew the retaining nut (11) .

  • Page 17: Barrel Removal

    SERVICE Barrel Removal Fluid Tube Remove the retaining nut, air cap, and spray tip. 20a Washer Cap Screw Unscrew the fluid tube connector (FF) at the bot- Wrench tom of the fluid tube (20), then pull the tube out of the Fluid Tube Connector inlet.

  • Page 18: Fluid Needle Replacement

    SERVICE Fluid Needle Replacement 17a Adjustment Nut Remove the gun barrel (9) as instructed on page 17. If the power cartridge comes out, carefully press Bottom of 63c Pressing Tool it back into the handle. thread Insert the narrow end of the pressing tool (63c) through the front of the gun to push the needle back, then remove the nut (21) and the adjustment nut (17a).

  • Page 19: Power Cartridge Replacement

    SERVICE Power Cartridge Turbine Alternator O–Rings Plug O–Ring Spring O–Ring Gasket Barrel Cushion Gun Handle See NOTE after step 3, below. NOTE: The power cartridge (1) includes items 1a–1c, and 3a–3c. Fig 19 Power Cartridge Replacement Remove the barrel as described under Barrel NOTE: The cushion (9b) is part of the gun barrel and should never be removed.

  • Page 20: Turbine Alternator Removal

    SERVICE Turbine Alternator Removal Slide the turbine alternator (1a) onto the power supply, being sure to align the coupling between the Remove the power cartridge from the gun power supply and the turbine alternator housing. handle as described under Power Cartridge Then twist the turbine alternator clockwise to lock the Replacement.

  • Page 21: Fan Air Valve Replacement

    SERVICE Fan Air Valve Replacement Air Valve Replacement Turn the fan adjusting knob (48) fully clockwise . Using a screwdriver, remove the retainer (57), spring (55), and air valve (54). See Fig 23. Place a wrench on the flats of the air valve hous- ing (47) and remove it from the handle (32).

  • Page 22: Muffler, Check Valve & Inlet Filter Replacement

    SERVICE ES ON–OFF Valve Removal & Replacement Regulator Disk Loosen and remove the nut (49). Remove the O–Ring Wave Washer lever (51) and washer (50). See Fig 24. Insert the hex Air Valve Valve Lever head wrench (63e) into the hex end of the valve (38), and loosen and remove the valve.

  • Page 23: Repair Kits

    Repair Kits must be purchased separately. Use only GENUINE GRACO PARTS AND ACCESSORIES. WARNING When servicing use only genuine Graco replacement parts. Use of other parts or any modification of the gun could alter the grounding continuity of the gun or cause parts to rupture and result in serious injury, fire, explosion, electrostatic shock, or property damage.

  • Page 24: Parts Drawing

    PARTS DRAWING Part No. 218–668, Series B Model PRO AA4000 Gun Apply Loctite – 801-21. Torque to 3.4 N m (25 in-lb) REF 28 76 77 13a* REF 17 *20a Ref No 63, Tool Kit *20a Includes items 63a–63g REF 32...

  • Page 25: Parts List

    MUFFLER charge from Graco. WARNING When servicing use only genuine Graco replace- ment parts. Use of other parts or any modification of the gun could alter the grounding continuity of the gun or cause parts to rupture and result in seri- ous injury, fire, explosion, electrostatic shock, or property damage.

  • Page 26: Accessories

    ACCESSORIES Accessories must be purchased separately. Use only GENUINE GRACO PARTS AND ACCESSORIES. WARNING NEVER operate your equipment at a working pressure rating that is higher than the lowest rated component in your system. Lower rated components may not be able to withstand the pressure developed by the pump and may rupture, causing serious bodily injury or property damage.
  • Page 27 106–148 Air Filter 501–511 Compression Spring 101–696 Fluid Pressure Gauge Pro AA4000 10:1 Ratio Monark Cart 0–70 bar (0–1000 psi) range System 230–984 Includes System 230–987, 10:1 Ratio Monark Pump, Fluid Filters Cart, and additional accessories 207 bar (3000 psi) MAXIMUM WORKING PRESSURE Pro AA4000 10:1 Ratio Monark Pail Part No.
  • Page 28 Not for use in Hazardous areas. Warning Signs Gun Cover 218–374 FM Approved Package of 10 disposable gun covers. Available from Graco at no extra charge. Must be ordered separately. Electrode Wires 218–751 Box of 10 replacement electrode wires for spray tip. Part No.

  • Page 29: Technical Data

    GRACO PHONE NUMBERS TECHNICAL DATA TO PLACE AN ORDER , contact your Graco distribu- Weight ......

  • Page 30: Spray Tip Selection Chart

    SPRAY TIP SELECTION CHART Fan Width at Light to Medium Part Number 300 mm (12 in.) Orifice Size Viscosity* Heavy Viscosity mm (in.) mm (in.) ml/min (fl oz/min) liters/min ((fl oz/min) 219–107 50–100 (2–4) 0.178 (0.007) 100 (3.4) 219–207 100–150 (4–6) 219–307 150–200 (6–8) 219–209...
  • Page 31 SPRAY TIP SELECTION CHART Fan Width at Light to Medium Heavy Part Number 300 mm (12 in.) Orifice Size Viscosity* Viscosity* mm (in.) mm (in.) ml/min (fl oz/min) liters/min ((fl oz/min) 219–319 150–200 (6–8) 0.483 (0.019) 800 (27.0) 600 (20.3) 219–419 200–250 (8–10) 219–519...

  • Page 32: Warranty

    Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defective.

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